High-lift grouting for
high-volume jobs
With a pump, grout a one-story height in 1 day
F
illing masonry walls or columns
with grout provides additional
strength. It enables load-bearing
masonry walls to be used for high-rise
structures and in areas of severe earth-
quakes. For instance, grouting the col-
lar joint of a cavity wall and the verti-
cal cells of hollow block or pilaster
units increases a wall’s compressive
and flexural strengths. When vertical
steel reinforcement is specified, the
grout transfers the load from the ma-
sonry units to the steel.
Two basic methods
There are two ways to place grout:
low-lift grouting and high-lift grout-
ing. In low-lift grouting, usually no
more than a 4-foot height of wall is
grouted in 1 day and no cleanouts are
used. Small amounts of grout are
placed by hand with buckets. In high-
lift grouting, cleanouts are used and up
to a full story height is poured in 1 day
using a grout pump.
Which method is better depends on
the type of masonry, the project size,
the equipment available, and your ex-
perience. One masonry contractor says
it’s not economical to set up a pump
and have a ready mix truck deliver
grout if the job requires less than 6 cu-
bic yards of grout.
High-lift grouting advantages
Waiting to grout until the wall is laid
up to a full story height has advan-
tages. In many areas of the country,
this allows the masons to install the
vertical steel after the wall is laid (but
before it’s grouted). This means the
masons can lay block without obstruc-
tions. They don’t have to thread block
over the tops of projecting rebar.
Workers also can place a large
amount of grout at one time. A grout
pump (which is expensive) is required,
but it reduces labor cost and can be
used again on different jobs. One crew
trained for grout placement can move
the pump from site to site, enabling
higher productivity and more consis-
tent workmanship.
The grout crew
A typical crew for a high-lift grout-
ing operation using a grout pump has
four workers. One handles the pump
hose, directing the grout into position;
another helps move the hose and pre-
vents it from getting snagged. A third,
working next to the hose, uses a pud-
dling stick or vibrator to consolidate
the grout. The fourth worker operates
the pump, directs the ready mix truck
traffic, and maintains consistent, uni-
form flow of grout through the hose.
For high-lift grouting, grout with a
slump between 5 and 7 inches is de-
livered to the project in ready mix
trucks. Water and approved admix-
tures may be added at the site to obtain
the desired fluidity before pumping.
Most specifications require the grout
to obtain a 28-day compressive
strength in excess of 2000 psi and to
Holes are knocked into the bottom
course of masonry to clean out the
cores that contain rebar. Before the
cores are grouted, these openings are
covered with plywood forms.
have a maximum coarse aggregate size
less than 3/8 inch.
Inspection is crucial
A perfect grouting operation may be
useless if the masonry wall is not prop-
erly constructed. So before you start
grouting be sure the wall construction
has been inspected. Some building of-
ficials don’t allow grout placement un-
til a government inspector has ap-
proved the construction. If this is not
required in your area, you should per-
form the inspection. Make sure all the
following are completed:
• Cleanouts are provided for each
pour in the bottom course of un-
grouted masonry.
• All debris and mortar are removed
from cores using the access provid-
ed by the cleanouts.
• Vertical cells have an unobstructed
vertical alignment of not less than
2x3 inches.
• All vertical and horizontal rein-
forcement is properly positioned
and secured in place before grout-
ing.

Ready mix trucks discharge grout into
a trailer-mounted grout pump that
transports it to the hoseman on the
wall.
• When grouting collar joints vertical
grout barriers or dams are provided
and located no more than 30 feet
apart.
• Cleanouts are closed with face shell
plugs or covered with forms.
• For cavity wall construction, ties
(made from at least #4 wire) are laid
at no more than 24 inches on center
horizontally and 16 inches on center
vertically.
• To gain sufficient strength before
grouting, double-wythe masonry is
cured for 3 days and single-wythe
masonry for 24 hours.
The grouting procedure
Grout for high-lift grouting usually
is supplied by ready mix trucks and
pumped into place. The grout pump
used should quickly transport the grout
to the point of deposit without segre-
gation of the mix. Try not to splatter
the grout on flashing, masonry units,
and other items. Discard the grout if
it’s not in place within 2 1/2 hours af-
ter water is first added.
For economical placement, pump a
uniform height of grout not to exceed a
4-foot lift. Immediately after place-
ment, consolidate the grout by vibra-
tion. Construction specifications usu-
ally require the lift to be vibrated
within 10 minutes after pouring.
Don’t place the next grout lift right
away. Wait 30 to 60 minutes. This
waiting period allows about 5% initial
consolidation of grout due to settle-
ment and absorption of excess water
by masonry units. Also, because the
grout is stiffening, the hydrostatic
pressure of the grout on the masonry
unit decreases. This reduces the possi-
bility of a mortar joint blowout.
After the waiting period, but while
the grout is still plastic, pour and then
vibrate the next lift. Extend the vibra-
tor through the new lift and into the
top 12 to 18 inches of the preceding
lift. Penetrating the preceding lift
bonds the two lifts and reconsolidates
the grout, closing plastic shrinkage
cracks and spaces between rebar or
units.
For the top lift, reconsolidate after
the necessary waiting period and fill
any open space left by settlement
shrinkage with grout. Keep the mason-
ry work and top of the grout pour cov-
ered and damp to prevent too rapid
drying during hot or dry weather and
drying winds.
Precautions
High-lift grouting can be quite eco-
nomical. There are problems, howev-
er, that contractors should avoid:
• Blowouts
• Vertical cell obstructions
• Construction joints in the grout
A blowout occurs when the hydro-
static grout pressure is greater than
what the mortar joint can resist. This
can be caused by not providing the re-
quired curing period for the mortar (24
After every 4-foot grout lift is poured,
workers vibrate the grout, being sure to
extend the vibrator into the top 12 to
18 inches of the previous lift.
hours for concrete block and 3 days for
double-wythe walls). Cold or dry
weather may extend this curing period
to 48 hours for core grouting and 5
days for collar joint grouting.
Obstructions in the collar joint or
block cores usually are caused by ex-
cess mortar droppings or trash that has
fallen inside them. If excess mortar to-
gether with the vertical steel obstructs
the opening, creating a void in the
grout core, the strength of the wall will
be reduced at this section.
High-pressure water jetting used
twice daily can remove mortar drop-
ping and other unwanted debris in
open collar joints. But be sure water
coming out the cleanouts is channeled
away so it doesn’t stain floors or walls.
Careful workmanship followed by
hand-cleaning can keep block cores
open.
Horizontal construction joints in the
grout are desirable only at the full sto-
ry height. Because of delays in receiv-
ing grout or breakdowns in equipment,
joints may be unavoidable at other lo-
cations. If the grouting is to be stopped
for 1 hour or longer, form the horizon-
tal construction joint by stopping the
grout 1 1/2 inches below a masonry
unit. Also, use a vibrator to reconsoli-
date the lift as soon as settlement
shrinkage occurs.
With a trained crew, a pre-grouting
inspection, and a few simple precau-
tions, your high-lift grouting operation
will consistently keep money in your
pocket.
—by Bruce Suprenant
PUBLICATION #M880060
Copyright © 1988, The Aberdeen Group
All rights reserved